High power, multi-phase, AC power contact arc suppressor

ABSTRACT

An arc suppressing circuit configured to suppress arcing across a power contactor coupled to an alternating current (AC) power source having a predetermined number of phases, each contact of the power contactor corresponding to one of the predetermined number of phases includes a number of dual unidirectional arc suppressors equal to the predetermined number of phases of the AC power source. Each dual unidirectional arc suppressor includes a first phase-specific arc suppressor configured to suppress arcing across the associated contacts in a positive domain, a a second phase-specific arc suppressor configured to suppress arcing across the associated contacts in a negative domain, and a coil lock controller, configured to be coupled between a contact coil driver of the power contactor, configured to detect an output condition from the contact coil driver and inhibit operation of the first and second phase-specific arc suppressors over a predetermined time.

PRIORITY

This application is a continuation of U.S. patent application Ser. No.17/030,738, filed. Sep. 24, 2020, which application is a continuation ofU.S. patent application Ser. No. 16/776,339, filed Jan. 29, 2020, issuedon Oct. 27, 2020 as U.S. Pat. No. 10,818,444, which application claimsthe benefit of priority to U.S. Provisional Application Ser. No.62/798,316, filed Jan. 29 2019; U.S. Provisional Application Ser. No.62/798;323, filed Jan. 29, 2019; and U.S. Provisional Application Ser.No. 62/798,326, filed Jan. 29, 2019, the contents of all which areincorporated herein by reference in their entireties.

TECHNICAL FIELD

The present application relates generally to a high power multi-phase ACpower contact arc suppressor.

BACKGROUND

Electrical current contact arcing may have deleterious effects onelectrical contact surfaces, such as relays and certain switches. Arcingmay degrade and ultimately destroy the contact surface over time and mayresult in premature component failure, lower quality performance, andrelatively frequent preventative maintenance needs. Additionally, arcingin relays, switches, and the like may result in the generation ofelectromagnetic interference (EMI) emissions. Electrical current contactarcing may occur both in alternating current (AC) power and in directcurrent (L)C) power across the fields of consumer, commercial,industrial, automotive, and military applications. Because of itsprevalence, there have literally been hundreds of specific meansdeveloped to address the issue of electrical current contact arcing.

BRIEF DESCRIPTION OF THE DRAWINGS

Some embodiments are illustrated by way of example and not limitation inthe figures of the accompanying drawings.

FIG. I is a block diagram of a high power, multi-phase AC power contactarc suppressor system, in an example embodiment.

FIG. 2 is a block diagram of three dual unidirectional arc suppressorsin antiparallel configuration, in an example embodiment.

FIG. 3 is a block diagram of a coil lock controller, in an exampleembodiment.

FIG. 4 is a block diagram of example first and second phase-specific arcsuppressors, in an example embodiment.

FIG. 5 is a circuit diagram of an example implementation of first andsecond phase-specific arc suppressors and other components of a dualunidirectional arc suppressor, in an example embodiment.

FIG. 6 is a block diagram of a dual unidirectional arc suppressor, in anexample embodiment.

FIGS. 7A and 7B are timing diagrams for an arc suppressing circuit, inexample embodiments.

FIG. 8 illustrates an operation of an arc suppressor circuit illustratedusing a waveform 800 for a three-phase power system, in an exampleembodiment.

FIGS. 9A-9C are perspective views of an implementation of a dualunidirectional arc suppressor, in an example embodiment.

DETAILED DESCRIPTION

Multi-phase power systems are a common method of AC power generation andtransmission. The most common such multi-phase power is three-phasepower, in which power is transmitted along three conductors, one hundredtwenty degrees out of phase with respect to one another. As such, in amulti-phase power system, at any given time, the current on at least oneconductor is in the positive domain while the current on at least oneother conductor is in the negative domain. In balanced three-phase powersystems, the sum of the instantaneous currents is zero, which may, on asystem level, inhibit attempts to suppress arcs at contacts in thethree-phase system. Moreover, because of the constant cycling of eachline of the three-phase system above and below the zero crossing,conventional arc suppressors may struggle with the resultant currentdensities,

Systems and methods have been developed to utilize arc suppressors tosuppress arc formation at the earliest stages in multi-phase AC powerarc generation and any related situation. By incorporating one dualunidirectional arc suppressor per phase of the multi-phase power system,the arc suppressing circuit as a whole is capable of suppressing arcs onall phases and in the positive and negative domains. The dualunidirectional arc suppressors each incorporate two separate arcsuppressors, one to deal with arcing in the positive domain and one todeal with arcing in the negative domain. Each individual arc suppressoris automatically switched in and out by a trigger latching switch, suchas a thermistor, that automatically cuts in and out as the alternatingcurrent transitions across the zero line.

FIG. 1 is a block diagram of a high power, multi-phase AC power contactarc suppressor system, in an example embodiment. The arc suppressingcircuit 1 and a power contactor 2 may be any suitable AC powergeneration mode, e.g., single-phase, three-phase, or multi-phasegenerally. The power contactor 2 includes first contacts 10A and secondcontacts 10B between which switches or other mechanisms known in the artmay open and close. A contactor coil driver 3 may be any of a variety ofcoil drivers known in the art, e.g., a process controller, an automationcontroller, an auxiliary relay, a manual switch, a contactor contact, arelay contact, and a semiconductor driver. An AC power source 4 providesAC power to an AC power load 5 by way of the power contactor 2. Powercontact line termination 67, 77, 87 and power contact terminaltermination 68, 78, 88 provides electrical coupling for the arcsuppressing circuit 1 across the power contactor 2. First and secondcontactor coil terminal terminations 91, 92 provide input to the arcsuppressing circuit 1 of the operation of the coil driver 3.

FIG. 2 is a block diagram of three dual unidirectional arc suppressorsin antiparallel configuration, in an example embodiment. The dualunidirectional arc suppressors are illustrated in specificimplementations in other figures disclosed herein which may beincorporated on a block level where appropriate or desired. As such, itis contemplated that the various blocks of the arc suppressing circuit 1may be implemented according to any permutation or combination of blockimplementations disclosed herein.

The arc suppressing circuit 1 includes three (3) dual unidirectional arcsuppressors 6, 7, 8 in an antiparallel configuration. Each of the dualunidirectional arc suppressors 6, 7, 8 includes blocks that will bedescribed in detail herein. Each block of each dual unidirectional arcsuppressor 6, 7, 8 may be separately implemented within each dualunidirectional arc suppressor 6, 7, 8 according to the requirements ofeach dual unidirectional arc suppressor 6, 7, 8. However, it is to berecognized and understood that each related component of each dualunidirectional arc suppressor 6, 7, 8 may be implemented according tocommon principles, and that the discussion of one such component withrespect to one dual unidirectional arc suppressor 6, 7, 8, e.g., a coillock controller 61 of dual unidirectional arc suppressor 6, may beunderstood to correspond to the related component of a different dualunidirectional arc suppressor 6, 7, 8, i.e., the coil lock controller 71of dual unidirectional arc suppressor 7 and the coil lock controller 81of dual unidirectional arc suppressor 8.

While three-phase systems are detailed herein, it is to be recognizedand understood that the principles disclosed with respect to three-phasesystems may be applied to any single or multi-phase AC power system.More broadly, for any system with a predetermined number of phases, thearc suppressing circuit I may be implemented with as a number of dualunidirectional arc suppressors equal to the predetermined number ofphases in the system in which the arc suppressing circuit i is beingutilized. Moreover, it is noted that the arc suppressing circuit 1 maybe utilized in a single phase AC or in a DC system.

Each dual unidirectional arc suppressor 6, 7, 8 includes a coil lockcontroller 61, 71, 81, respectively; a first, phase-specific singleunipolar arc suppressor 62, 72, 82, respectively; and a secondphase-specific single unipolar arc suppressor 63, 73, 83, respectively;coupled to one another at nodes 611, 711, 811, respectively, and nodes612, 712, 812, respectively. Each dual unidirectional arc suppressor 6,7, 8 further includes a second overvoltage protector 69, 79, 89,respectively, coupled to the first and second phase-specific singleunipolar arc suppressors 62, 63,72, 73, 82, 83, at node 640, 740, 840,respectively and nodes 681, 781, 881, respectively. Examples of the coillock controllers 61, 71, 81, first, phase-specific single unipolar arcsuppressor 62, 72, 82, and second phase-specific single unipolar arcsuppressor 63, 73, 83, will be disclosed in detail herein. The secondovervoltage protectors 69, 79, 89 may be or may be comprised of avaristor, a transient-voltage suppression (TVS) diode, a Zener diode; agas tube, a spark gap, or any other related, suitable component to lockout the associated arc suppressor 6, 7, 8 when the associated arcsuppressor 6, 7, 8 is not needed for arc suppression.

A fusible trace or fusible element 641, 741 841, respectively, may, overan extended length of the fusible element 641, 741 841, be void oforganic material, such as solder mask, silkscreen, and the like.Additionally or alternatively, the fusible element 641, 741, 841 mayinclude passive or active fuse elements known in the art. The fusibleelements 641, 741, 841 are coupled to node 640, 740, 840, respectively.Finally, each dual unidirectional arc suppressor 6, 7, 8 includes apower contact line termination 67, 77, 87 coupled to node 671, 771, 871,respectively, and a power contact terminal termination 68, 78, 88,respectively, coupled to nodes 681, 781, 881, respectively,

Each dual unidirectional arc suppressor 6, 7, 8 is configured to operateat a separate phase in a three-phase system relative to one another.Thus, by way of illustrative example, if the first dual unidirectionalarc suppressor 6 is configured to operate at zero degree phase, thesecond dual unidirectional arc suppressor 7 may be configured to operateat plus-one hundred twenty degrees out of phase with the first dualunidirectional arc suppressor 6 while the third dual unidirectional arcsuppressor 8 may be configured to operate at negative-one hundred twentydegrees out of phase with the first dual unidirectional arc suppressor8. (See FIG. 8 .) In such an example, each dual unidirectional arcsuppressor 6, 7, 8 is configured to receive one of three correspondinglines of a three-phase power line and suppress arcing on that line.

As will be illustrated herein, each dual unidirectional arc suppressor6, 7, 8 is “dual” because each includes two separate arc suppressors. Invarious examples, the dual unidirectional arc suppressor 6, 7, 8 may be“unidirectional” by being configured to operate from the power source tothe load, i.e., in a single direction, rather than handlingbidirectional current flow. While unidirectional arc suppressors aredisclosed, the examples described herein may be implemented on anysuitable arc suppressor dependent on the circumstances of use.

The arc suppressing circuit 1 further incorporates a coil interface 90.In the illustrated examples, the coil interface 90 includes: first andsecond contactor coil terminal terminations 91, 92; a coil power overcurrent protection 93, which is coupled to the second contactor coilterminal termination 92 at node 921; and a coil power over voltageprotection 94, which is coupled between nodes 911 and 931, which arecoupled with the coil lock controllers 61, 71, 81. In an example, thecoil power over current protection 93 is a resistor and the coil powerover voltage protection 94 is a varistor, but it is to be recognized andunderstood that any suitable components may be in the coil power overcurrent protection 93 and over voltage protection 94. The coil interface90 is configured to receive an output condition of the contactor coildriver 3 and output a signal based on the output condition to the coillock controllers 61, 71, 81.

The arc suppressing circuit 1 may be implemented as hardware accordingto any suitable method or mechanism, including as a single componentsubstrate or printed circuit board, a common motherboard, and/or asseparate daughter boards. An internal shield or shielding system mayincorporate shielding features 643, 644, 743, 744, 843, 844, such asdeflectors, baffles, and/or blow holes, or slots to control, guide, anddissipate shock waves. The shielding features 643, 644, 743, 744, 843,844 may, in an example, be made in whole or in part from 0.3556millimeter (0.014 inch) thick FR4 fiberglass. The arc suppressingcircuit 1 may further include trace barriers 645, 646, 745, 746, 845,846 and plasma blast shields 647, 747, 847. The shielding componentscollectively 643, 644, 645, 646, 647 743, 744, 745, 746, 747, 843. 844,845. 846, 847 may act to catch and contain detritus and may act as asublimate receptor.

In various examples, a fuse (see FIGS. 9A-9C) may be incorporated on abottom, i.e., unpopulated side of an enclosure of the arc suppressingcircuit 1 In such an example, the fuse may not incorporate a conformalmask or conformal coating. Incorporation of the fuse on the bottom sidemay help isolate resultant debris in the event of failure of the fusefrom other components while also providing relative ease ofmanufacturing owing to access for soldering or other coupling orattachment mechanisms. An epoxy silkscreen bridge may minimize soldercreep into the fuse. The fuse is inline with the quick-connect terminal(QCT) tab and circuitry of the arc suppressing circuit 1 to minimizevaporized copper on proximate components.

The arc suppressing circuit 1 may incorporate various physical andelectrical separation features as well as dielectric isolation features,which are described in FIGS. 9A-9C. Dielectric isolation may includephase separation of at least one thousand five hundred (1,500) Voltdielectric isolation between each phase in a conventional one hundredtwenty (120) Volt application, but it is to be recognized and understoodthat the dielectric isolation may be set according to the use in whichthe arc suppressing circuit 1 is being used.

FIG. 3 is a block diagram of a coil lock controller, in an exampleembodiment. The coil lock controller 61 may be implemented as any one orall of the coil lock controllers 61, 71, 81 of the dual unidirectionalarc suppressors 6, 7, 8. The coil lock controller 61 includes a powerconverter 615, a rectifier 616, a power limiter 617, a power storage618, a current supply 619, and, optionally, an enabled indicator 620.The enabled indicator 620 may provide an external indication that thecoil lock controller 61 and the associated dual unidirectional arcsuppressor 6, 7, 8 generally is in an enabled state and ready tosuppress contact arcing. The enabled indicator I may be an interface,such as a user interface, e.g., a light emitting diode (LED) or otherlight source, or an input/output (110) port, such as an externalconnection, internal communication link via microprocessor ormicrocontroller to communicate with external equipment via wired orwireless modalities.

The coil power converter 615 may function as a regulator and/or limiteron the input power to the coil lock controller 61. In an example, thecoil power converter 615 may be comprised of a capacitor in series witha resistor. The capacitor may pass AC current and block DC current. Theresistor may limit inrush and steady state current. However, the coilpower converter 615 may be implemented with any hardware that mayregular and/or limit input power.

The rectifier 616 may be or may include diodes, valves, bridgerectifiers, and the like. The power limiter 617 may be or may include aZener diode, a TVS, a varistor, and the like. The current supply 619 maybe any suitable current source, including a voltage supply thatincorporates a current limiter.

The power storage 618 may be a holdover power storage deice to hold overfrom the contactor coil driver 3 for a relatively short period of time,e.g, one hundred milliseconds to three hundred milliseconds, in order tokeep the coil lock controller 61 in an unlocked state for apredetermined time sufficient to allow the contactor coil driver 3 tode-energize and allow time for the power contactor 2 to break or makecontact, as will be illustrated herein. In various examples, the powerstorage 618 may be or may include a microprocessor or other controllerto control an actual holdover time, i.e., may provide active holdoverpower control, in contrast to components that may provide passiveholdover power control, as disclosed herein.

FIG. 4 is a block diagram of example first and second phase-specific arcsuppressors, in an example embodiment. The first phase-specific arcsuppressor 62 may be implemented as any one or more of the firstphase-specific single unipolar arc suppressors 72, 82. The secondphase-specific arc suppressor 63 may be implemented as any one or moreof the second phase-specific single unipolar arc suppressors 73, 83.Thus, in various examples, the blocks described with respect to thefirst and second phase-specific arc suppressors 62, 63 may beimplemented in the same way as the other first and second phase-specificarc suppressors 72, 73, 82, 83, with their roles determined by how theyare wired with respect to one another and the other system components.Alternatively, the various blocks may be implemented in different waysbetween and among the various first and second phase-specific arcsuppressors 62, 63, 72, 73, 82, 83.

In examples where the first and second phase-specific arc suppressors62, 63 are implemented as the first and second phase-specific arcsuppressors 72, 73, the node 611 is instead coupled to node 711, thenode 612 is instead coupled to node 712, the node 640 is instead coupledto node 740, and the node 681 is instead coupled to node 781, as shownin FIG. 2 . In examples where the first and second phase-specific arcsuppressors 62, 63 are implemented as the first and secondphase-specific arc suppressors 82, 83, the node 611 is instead coupledto node 811, the node 612 is instead coupled to node 812, the node 640is instead coupled to node 840, and the node 681 is instead coupled tonode 881, as shown in FIG. 2 .

For the purposes of illustration, the first phase-specific arcsuppressor 62 is configured to suppress contact arcing for positivehalfwaves of AC current, i.e., the portion of the current above thezero-degree phase line of a sinusoidal AC current as illustrated in FIG.8 . The second phase-specific arc suppressor 63 is configured tosuppress contact arcing for negative, i.e., the portion of the currentbelow the zero-degree phase line of the sinusoidal AC current, asillustrated in FIG. 8 .

In the illustrated example, the first and second phase-specific arcsuppressors 62, 63 each respectively include the following components:

A signal edge detector 621, 631 is configured to generate an outputbased on receiving a change in a voltage signal from the contactsindicative of a contact separation event or a plasma ignition event. Invarious examples, the signal edge detector may be any component orcomponents that produce a change in output based on receipt of a voltageedge.

An edge-pulse converter 622, 632, is configured to convert the voltageedge from the signal edge detector 621, 631, respectively, to a digitalpulse. The edge-puke converter 622, 632 may be a transformer, pulsetransformer, gate trigger, or any other suitable component.

A current limiter 623, 633, is configured to limit the current throughthe signal edge detector 621, 631, respectively, and edge-pulseconverter 622, 632, respectively. The current limiter 623, 633 may be arelatively high impedance component or components, such as a resistor.

A first over voltage protection 624, 634 prevents excessive voltage frompropagating through the first and second phase-specific arc suppressors62, 63, respectively. The first over voltage protection 624, 634 may bea varistor, a TVS diode, a Zener diode, a gas tube, a spark gap, or anyother related, suitable component.

A coil lock 60, 600 is configured to disable the first and secondphase-specific arc suppressors 62, 63, respectively, when one or both ofthe first and second phase-specific arc suppressors 62, 63 are subjectedto a fast input voltage rising edge during the initial supply of powerto the contact that the first and second phase-specific arc suppressors62, 63 are connected across. In the illustrated example, the coil locks60, 600 include a signal isolator detector 625, 635, respectively, and asignal isolator emitter 626, 636, respectively. In various examples,those parts of the coil locks 60, 600 may be implemented as a singlecomponent, such as a photorelay, or as separate components,

Current valves 627, 628, 637, 638 are configured to enable current flowin only one direction, such as a diode rectifier, tube valve, and soforth.

Signal terminators 629, 639 may be any component with suitableimpedance, such as a resistor.

A latching switch 6212, 6312, is configured to engage or disengage itsrespective first and second phase-specific arc suppressors 62, 63 basedon the input to the gate of the latching switch 6212, 6312 beingpositive or negative. In such an example, owing to the differing phasesof the first and second phase-specific arc suppressors 62, 63, only onelatching switch 6212, 6312 allows current to pass through at a time,limiting the operation to only one of the first and secondphase-specific arc suppressors 62, 63 at a time. As such, in an example,the latching switches 6212, 6312 are thyristors or related devices suchas TRIACs or silicon controlled rectifiers (SCRs).

In the illustrated example, the first and second phase-specific arcsuppressors 62, 63 each respectively include the following optionalcomponents which may be utilized in circumstances in which the first andsecond phase-specific arc suppressors 62, 63 are designed for relativelyhigh current conditions, e.g., at least one (1) kiloampere:

A current valve 6210, 6310. Current limiters 6211, 6213, 6311, 6313.Signal termination 6214, 6314. Over voltage protection 6215. A triggerlatching valve 6216, 6316, such as a thyristor, TRIAC, SCR, and soforth.

Finally, the first and second phase-specific arc suppressors 62, 63share a second over voltage protector 69.

FIG. 5 is a circuit diagram of an example implementation of the firstand second phase-specific arc suppressors 62, 63 and other components ofthe dual unidirectional arc suppressor 6, in an example embodiment. Aswith the block diagram of FIG. 4 , it is to be recognized and understoodthat the specific implementation of the dual unidirectional arcsuppressor 6 may also be implemented as the dual unidirectional arcsuppressors 7, 8, as adjusted for the various nodes to which those dualunidirectional arc suppressors 7, 8 are coupled, as shown in FIG. 2 .

In the illustrated example, the coil interface 90 includes the coilterminals 91, 92; the coil over current protection 93 as a ten (10) Ohmresistor; and the coil over voltage protection 94 as a four hundredseventy (470) Volt, four hundred (400) Ampere varistor.

In the illustrated example, the coil lock controller 61 includes thepower converter 615 as a parallel one thousand (1,000) Ohm resistor anda 0.1 microfarad, six hundred thirty (630) Volt ceramic capacitor; therectifier 616 as one hundred (100) Volt, two hundred fifteen (215)milliampere diode arrays; the power limiter 617 as an eighteen (18) VoltZener diode; the power storage 618 as a one hundred (100) microfarad,twenty-five (25) Volt aluminum electrolytic capacitor; and the currentsupply 619 as a six hundred (600) Volt N-channel MOSFET transistor.

In the illustrated example, the first and second phase-specific arcsuppressors 62, 63 each include, respectively:

The signal edge detector 621, 631 as a 0.022 microfarad one (630)kilovolt capacitor; the pulse edge converter 622, 632 as a two coil, ten(10) microhenry inductor array; the current limiter 623, 633 as a ten(10) Ohm resistor; the first over voltage protection 624, 634 as a six(6) Volt TVS; the coil lock 60, 600 as a two (2) Ampere, forty (40) Voltphotorelay; the current valves 627, 628, 637, 638 as three hundred (300)Volt, one (1) Ampere diodes; the signal terminators 629, 639 as onehundred (100) Ohm resistors; and the latching switch 6212, 6312 as anon-isolated, one (1) kilovolt, fifty-five (55) Ampere SCR.

In the illustrated example, the second over voltage protector 69 is aneight hundred twenty (82.0), 1.2 kiloampere varistor. The fusibleelement 641 and power contact line termination 67, 68 are provided forthe purposes of illustration. A ready indicator 642 in the form of alight emitting diode is also provided.

FIG. 6 is a block diagram of the dual unidirectional arc suppressor 6,in an example embodiment. The block diagram illustrates the topologyfeatures of the dual unidirectional arc suppressor 6 in relation to thevarious blocks disclosed herein. In particular, nodes 640 and 681 areimplemented as conduction and cooling structures and are physicallywider than a conventional trace. The shielding features 643, 644 bracketthe fusible element 641 to contain any physical consequence of a failureof the fusible element 641. The relative positioning of the variousblocks 61, 62, 63, 69, 642 and nodes 611, 621, 671, 911, 931 may berepresentative of the positioning of those blocks and nodes in animplemented board or finished product.

FIGS. 7A and 7B are timing diagrams for the arc suppressing circuit 1,in example embodiments. In general, the timing diagrams illustratesignals as detected by or transmitted from the coil lock controller 61,71, 81 of the respective dual unidirectional arc suppressors 6, 7, 8 andcurrent and voltage over the contacts of the power contactor 2. Thetiming diagrams proceed over time from left to right.

The timing diagram of FIG. 7A depicts the operation of the arcsuppressing circuit I when the power contact 2 is a normally-open, e.g.,Form A, power contact. At 750, the system is in a base state, with thecoil voltage low, the contact current low, the contact voltage high, andthe lock state of the coil lock circuit 61, 71, 81 low or “locked”,inhibiting operation of the arc suppressing circuit 1. At 752, the coilvoltage from the contactor coil driver 3 rises to high, indicating animpending closing of the contact 2, and providing a high voltage acrossthe input nodes 911, 931 to the coil lock circuits 61, 71, 81. At 754,the coil lock circuits 61, 71, 81 output on the output nodes 611, 612 ahigh, unlock signal, enabling operation of their respective dualunidirectional arc suppressors 6, 7, 8.

At 756, the current rises and the voltage falls across the powercontactor 2 as the contacts close, causing the activation of the dualunidirectional arc suppressors 6, 7, 8 to suppress resultant arcing.Between 756 and 758, arclets form and are suppressed by the dualunidirectional arc suppressors 6, 7, 8. The phenomenon of arclets isdiscussed in U.S. Pat. No. 9,423,442, Henke, which is incorporatedherein in its entirety. At 758, owing to the operation of the dualunidirectional arc suppressors 6, 7, 8, the arclets are no longerforming and arcing across the power contactor 2 has been suppressed. Thepower contactor 2 remains closed over 760 and the arc suppressingcircuit 1 is not suppressing any arcing across the contacts.

At 762, the contactor coil driver 3 voltage rises, signaling animpending opening of the power contactor 2. At 764, resultant arcletsbegin, are suppressed by the dual unidirectional arc suppressors 6, 7,8, and last until 766, where the current has partially fallen and thevoltage has partially risen. At 768, the power contactor 2 is opened,the current is low and the voltage high across the power contactor 2. At770, with the voltage low across the input nodes 911, 931 to the coillock circuits 61, 71, 81, the output nodes 611, 612 go to a low, lockedstate. At 772, the system has returned to the base state as at 750.

The timing diagram of FIG. 7B depicts the operation of the arcsuppressing circuit 1 when the power contact 2 is a normally-closed,e.g., Form B, power contact. As will be seen, as a practical matter, thedifference in operation of the arc suppressing circuit 1 with a Form Bpower contact is that the coil lock circuits 61, 71, 81 return to alocked state when the power contactor 2 is closed after suppressingarcing across the power contactor 2 as the power contactor 2 open, butis then unlocked again when the power contactor 2 is opened.

At 774, the system is in a base state, with the coil voltage high, thecontact current low, the contact voltage high, and the lock state of thecoil lock circuit 61, 71, 81 low or “locked”, inhibiting operation ofthe arc suppressing circuit 1. At 776, the coil voltage from thecontactor coil driver 3 drops to low, indicating an impending closing ofthe contact 2, and providing a low voltage across the input nodes 911,931 to the coil lock circuits 61, 71, 81. At 778 the coil lock circuits61, 71, 81 output on the output nodes 611, 612 a high, unlock signal,enabling operation of their respective dual unidirectional arcsuppressors 6, 7, 8,

At 780, the current rises and the voltage falls across the powercontactor 2 as the contacts close, causing the activation of the dualunidirectional arc suppressors 6, 7, 8 to suppress resultant arcing.Between 780 and 782, arclets form and are suppressed by the dualunidirectional arc suppressors 6, 7, 8. At 782, owing to the operationof the dual unidirectional arc suppressors 6, 7, 8, the arclets are nolonger forming and arcing across the power contactor 2 has beensuppressed. The power contactor 2 remains closed at 784 and, owing tothe low coil voltage, high current, and low contact voltage, the coillock circuits 61, 71, 81 output a low, locked signal on their outputnodes 611, 612. The power contactor 2 remains closed over 786 and thearc suppressing circuit I is not suppressing any arcing across thecontacts.

At 788, the contactor coil driver 3 voltage rises, signaling animpending opening of the power contactor 2. At 790, the coil lockcircuits 61, 71, 81 output on the output nodes 611, 612 a high, unlocksignal, enabling operation of their respective dual unidirectional arcsuppressors 6, 7, 8. At 792, resultant arclets begin, are suppressed bythe dual unidirectional arc suppressors 6, 7, 8, and last until 794,where the current has partially fallen and the voltage has partiallyrisen. At 796, the power contactor 2 is opened, the current is low andthe voltage high across the power contactor 2. At 798, with the voltagelow across the input nodes 911, 931 to the coil lock circuits 61, 71,81, the output nodes 611, 612 go to a low, locked state. At 799, thesystem has returned to the base state as at 774.

FIG. S illustrates an operation of the arc suppressing circuit 1illustrated using a waveform 800 for a three-phase power system, in anexample embodiment. It is noted that while three-phase AC power has beenutilized for illustrative purposes, the principles disclosed hereinapply as well to any AC power system, including single phase systems andnon-three phase multi-phase systems.

The Y-axis 802 shows voltage or current amplitude relative to the phasein degrees along the X-axis or zero line 804. For the purposes of thisdisclosure, the positive domain 806 is all space above the zero line804, while the negative domain 808 is all space below the zero line 804.

For the purposes of this illustration, the first curve 810 representsthe input to the dual unidirectional arc suppressor 6, the second curve812 represents the input to the dual unidirectional arc suppressor 7,and the third curve 814 represents the input to the dual unidirectionalarc suppressor 8. For each dual unidirectional arc suppressor 6, 7, 8,when the input is in the positive domain 806 the first phase-specificarc suppressor 62, 72, 82, respectively, is active or potentially activewhile the second phase-specific arc suppressor 63, 73, 83, respectively,is inactive. For each dual unidirectional arc suppressor 6, 7, 8, whenthe input is in the negative domain 806 the first phase-specific arcsuppressor 62, 72, 82, respectively, is inactive while the secondphase-specific arc suppressor 63, 73, 83, respectively, is active orpotentially active. As noted herein, the switch from active to inactiveor vice versa occurs because the trigger latch switch 6212, 6312 goesfrom conducting to non-conducting or vice versa when the input crossesthe zero line 804.

At 816, the first curve 810 is crossing the zero line 804, and thesecond phase-specific arc suppressor 63 is switching from active toinactive and the first arc suppressor is switching from inactive toactive. The second curve 812 is in the negative domain 808 and thesecond phase-specific arc suppressor 73 is active and the firstphase-specific arc suppressor 72 is inactive. The third curve is in thepositive domain 806 and the first phase-specific arc suppressor 82 isactive and the second phase-specific arc suppressor 83 is inactive,

At 818, the third curve 814 crosses the zero line 804 into the negativedomain 808, and the first phase-specific arc suppressor 82 becomesinactive and the second phase-specific arc suppressor 83 becomes active.The other two dual unidirectional arc suppressors 6, 7, do not changetheir operating state.

At 820, the second curve 812 crosses the zero line 804 into the positivedomain 806, and the first phase-specific arc suppressor 72 becomesactive and the second phase-specific arc suppressor 73 becomes inactive.The other two dual unidirectional arc suppressors 6, 8, do not changetheir operating state.

At 822, the first curve 810 crosses the zero line 804 into the negativedomain 808, and the first phase-specific arc suppressor 62 becomesinactive and the second phase-specific arc suppressor 63 becomes active.The other two dual unidirectional arc suppressors 7, 8, do not changetheir operating state.

At 824, the third curve 814 crosses the zero line 804 into the positivedomain 806, and the first phase-specific arc suppressor 82 becomesactive and the second phase-specific arc suppressor 83 becomes inactive.The other two dual unidirectional arc suppressors 6, 7, do not changetheir operating state.

At 826, the second curve 812 crosses the zero line 804 into the negativedomain, and the first phase-specific arc suppressor 72 becomes inactiveand the second phase-specific arc suppressor 73 becomes active. Theother two dual unidirectional arc suppressors 6, 8, do not change theiroperating state.

FIGS. 9A-9C are perspective views of an implementation of the dualunidirectional arc suppressor 6, in an example embodiment.

FIG. 9A is a view of the underside 900 of a printed circuit board (PCB)902 including components of the dual unidirectional arc suppressor 6(not pictured). As an example, a chip 904 or other block includes thecoil lock circuit 61, the first phase-specific arc suppressor 62, thesecond phase-specific arc suppressor 63, and the ready indicator 642.The power contact line termination 67 and the power contact terminaltermination 68 bracket either end of the PCB 902. The fusible trace 641is bracketed on each short end by dielectric barriers 645, 646 and alongeach long side by shielding elements 643, 644. The dielectric barriers645, 646 may be of insulating materials, such as epoxy paint, silicone,and the like. The shielding elements 643, 644 may provide venting and adissipation mechanism for a supersonic plasma blast shockwave from thefusible trace 641. The fusible trace 641 is further covered by a plasmablast shield 647.

FIG. 9B and 9C are side perspectives of the PCB 902 to illustrate an airgap 906 between the underside 900 of the PCB 902 and the plasma blastshield 647. The plasma blast shield 647 may be situated on a housing ormay be held by standoffs or any other mechanism sufficient to provideand maintain the air gap 906.

Additional Examples

The description of the various embodiments is merely exemplary in natureand, thus, variations that do not depart from the gist of the examplesand detailed description herein are intended to be within the scope ofthe present disclosure. Such variations are not to be regarded as adeparture from the spirit and scope of the present disclosure.

Example 1 is an arc suppressing circuit configured to suppress arcingacross a power contactor coupled to an alternating current (AC) powersource having a predetermined number of phases, each contact of thepower contactor corresponding to one of the predetermined number ofphases, the arc suppressing circuit comprising: a number of dualunidirectional arc suppressors equal to the predetermined number ofphases of the AC power source, each dual unidirectional arc suppressorcoupled across the power contactor, each dual unidirectional arcsuppressor comprising: a first phase-specific arc suppressor configuredto suppress arcing across the associated contacts in a positive domain;a second phase-specific arc suppressor configured to suppress arcingacross the associated contacts in a negative domain; and a coil lockcontroller, configured to be coupled between a contact coil driver ofthe power contactor, configured to detect an output condition from thecontact coil driver and inhibit operation of the first and secondphase-specific arc suppressors over a predetermined time.

In Example 2, the subject matter Example 1 includes, wherein the firstphase-specific arc suppressor is configured to not suppress arcing inthe negative domain and the second phase-specific arc suppressor isconfigured to not suppress arcing in the positive domain.

In Example 3, the subject matter of any one or more of Examples 1 and 2includes, wherein each of the first and second phase-specific arcsuppressors comprise a latching switch configured to cause the first andsecond phase-specific arc suppressors to not suppress arcing in thenegative and positive domains, respectively.

In Example 4, the subject matter of any one or more of Examples 1-3includes, wherein the latching switch is a thyristor.

In Example 5, the subject matter of any one or more of Examples 1-4includes, wherein the coil lock controller comprises: a power convertercoupled over a coil interface; a rectifier coupled to the powerconverter; a power limiter coupled to the rectifier; a power storagecoupled to the power limiter; and a current supply coupled to the powerstorage, the current supply coupled to the first phase-specific arcsuppressor and the second phase-specific arc suppressor.

In Example 6, the subject matter of any one or more of Examples 1-5includes, wherein the power converter comprises an RC circuit, therectifier comprises a diode array, the power limiter comprises a Zenerdiode; the power storage comprises a capacitor; and the current supplycomprises a MOSFET transistor.

In Example 7, the subject matter of any one or more of Examples 1-6includes, wherein each of the first and second phase-specific arcsuppressors comprise a coil lock, coupled to the coil lock controller,configured to disable a respective one of the first and secondphase-specific arc suppressors based on an input from the coil lockcontroller.

In Example 8, the subject matter of any one or more of Examples 1-7includes, wherein the coil lock comprises a signal isolator emittercoupled to the coil lock controller and a signal isolator detectorcoupled to the latching switch.

In Example 9, the subject matter of any one or more of Examples 1-8includes, wherein the coil lock is a photorelay comprising the signalisolator emitter and the signal isolator detector.

In Example 10, the subject matter of any one or more of Examples 1-9includes, wherein each of the first and second phase-specific arcsuppressors comprises: a signal edge detector; an edge-pulse converterin series with the signal edge detector; a current limiter in serieswith the edge-pulse converter; and a first over voltage protectioncoupled to the edge-pulse converter and the signal isolator detector ofthe coil lock.

In Example 11, the subject matter of any one or more of Examples 1-10includes, wherein the edge-pulse converter is at least one of: atransformer; a pulse transformer; or a gate trigger.

In Example 12, the subject matter of any one or more of Examples 1-11includes, wherein each of the dual unidirectional arc suppressorsfurther comprises: a first contact terminal configured to beelectrically coupled to a first contact of the power contactor; a secondcontact terminal configured to be coupled to be electrically coupled toa second contact of the power contactor, the second contact terminalcoupled to the first phase-specific arc suppressor, the secondphase-specific arc suppressor, and the coil lock controller; and afusible element coupled between the first contact terminal and the firstphase-specific arc suppressor, the second phase-specific arc suppressor,and the coil lock controller.

In Example 13, the subject matter of any one or more of Examples 1-12includes, wherein the fusible element is one of: a solder mask, asilkscreen, a passive fuse, or an active fuse.

In Example 14, the subject matter of any one or more of Examples 1-13includes, wherein each of the dual unidirectional arc suppressorsfurther comprises a second over voltage protector coupled over the firstphase-specific arc suppressor, the second phase-specific arc suppressor,and the coil lock controller.

In Example 15, the subject matter of any one or more of Examples 1-14includes, wherein the second over voltage protector comprises at leastone of: variostor, a transient-voltage suppression (TVS) diode, a Zenerdiode, a gas tube, or a spark gap.

Example 16 is a three-phase arc suppressing circuit, comprising: a coilinterface, configured to be coupled to a contactor coil driver of apower contactor and to receive an output condition of the contactor coildriver and output a signal based on the output condition; a first dualunidirectional arc suppressor configured to be coupled to contacts at afirst phase, comprising: a first phase-specific arc suppressorconfigured to suppress arcing in a positive domain; a secondphase-specific arc suppressor configured to suppress arcing in anegative domain; and a coil lock controller, coupled to the coilinterface, configured to inhibit operation of the first and secondphase-specific arc suppressors over a predetermined time based on thesignal from the coil interface; a second dual unidirectional arcsuppressor configured to be coupled to contacts at a second phase onehundred and twenty degrees greater than the first phase, comprising: afirst phase-specific arc suppressor configured to suppress arcing in thepositive domain; a second phase-specific arc suppressor configured tosuppress arcing in the negative domain; and a coil lock controller,coupled to the coil interface, configured to inhibit operation of thefirst and second phase-specific arc suppressors over a predeterminedtime based on the signal from the coil interface; and a third dualunidirectional arc suppressor configured to be coupled to contacts at athird phase one hundred and twenty degrees less than the first phase,comprising: a first phase-specific arc suppressor configured to suppressarcing in the positive domain; a second phase-specific arc suppressorconfigured to suppress arcing in the negative domain; and a coil lockcontroller, coupled to the coil interface, configured to inhibitoperation of the first and second phase-specific arc suppressors over apredetermined time based on the signal from the coil interface.

Example 17, the subject matter of Example 16 includes, wherein thepredetermined time is selected to allow the contactor coil driver tode-energize and allow time for the power contactor to break or makecontact.

In Example 18, the subject matter of any one or more of Examples 15-17includes, wherein the first phase-specific arc suppressors areconfigured to not suppress arcing in the negative domain and the secondphase-specific arc suppressor is configured to not suppress arcing inthe positive domain.

In Example 19, the subject matter of any one or more of Examples 15-18includes, wherein each of the first and second phase-specific arcsuppressors comprise a latching switch configured to cause the first andsecond phase-specific arc suppressors to not suppress arcing in thenegative and positive domains, respectively.

In Example 20, the subject matter of any one or more of Examples 15-19includes, wherein the latching switch is a thyristor.

Example 21 is at least one machine-readable medium includinginstructions that, when executed by processing circuitry, cause theprocessing circuitry to perform operations to implement of any ofExamples 1-20.

Example 22 is an apparatus comprising means to implement of any ofExamples 1-20.

Example 23 is a system to implement of any of Examples 1-20.

Example 24 is a method to implement of any of Examples 1-20.

The above detailed description includes references to the accompanyingdrawings, which form a part of the detailed description. The drawingsshow, by way of illustration, specific embodiments. These embodimentsare also referred to herein as “examples.” Such examples may includeelements in addition to those shown and described. However, the presentinventor also contemplates examples in which only those elements shownand described are provided.

All publications, patents, and patent documents referred to in thisdocument are incorporated by reference herein in their entirety, asthough individually incorporated by reference. In the event ofinconsistent usages between this document and those documents soincorporated by reference, the usage in the incorporated reference(s)should be considered supplementary to that of this document; forirreconcilable inconsistencies, the usage in this document controls.

In this document, the terms “a” or “an” are used, as is common in patentdocuments, to include one or more than one, independent of any otherinstances or usages of “at least one” or “one or more.” in thisdocument, the term “or” is used to refer to a nonexclusive or, such that“A or B” includes “A but not B,”

“B but not A,” and “A and B,” unless otherwise indicated. In theappended claims, the terms “including” and “in which” are used as theplain-English equivalents of the respective terms “comprising” and“wherein.” Also, in the following claims, the terms “including” and“comprising” are open-ended, that is, a system, device, article, orprocess that includes elements in addition to those listed after such aterm in a claim are still deemed to fall within the scope of that claim.Moreover, in the following claims, the terms “first,” “second,” and“third,” etc. are used merely as labels, and are not intended to imposenumerical requirements on their objects.

The above description is intended to be, and not restrictive. Forexample, the above-described examples (or one or more aspects thereof)may be used in combination with each other. Other embodiments may beused, such as by one of ordinary skill in the art upon reviewing theabove description. The Abstract is provided to comply with 37 C.F.R. §1.72(b), to allow the reader to quickly ascertain the nature of thetechnical disclosure. It is submitted with the understanding that itwill not be used to interpret or limit the scope or meaning of theclaims. In addition, in the above Detailed Description, various featuresmay be grouped together to streamline the disclosure. This should not beinterpreted as intending that an unclaimed disclosed feature isessential to any claim. Rather, inventive subject matter may lie in lessthan all features of a particular disclosed embodiment. Thus, thefollowing claims are hereby incorporated into the Detailed Description,with each claim standing on its own as a separate embodiment.

1. (canceled)
 2. An arc suppressing circuit configured to suppressarcing across a power contactor coupled to an alternating current (AC)power source having a predetermined number of phases, each contact ofthe power contactor corresponding to one of the predetermined number ofphases, the arc suppressing circuit comprising: a number of dualunidirectional arc suppressors equal to the predetermined number ofphases of the AC power source, each dual unidirectional arc suppressorcoupled across the power contactor, each dual unidirectional arcsuppressor comprising: a first phase-specific arc suppressor configuredto suppress arcing across the associated contacts in a positive domain;a second phase-specific arc suppressor configured to suppress arcingacross the associated contacts in a negative domain; and a coil lockcontroller configured to inhibit operation of the first and secondphase-specific arc suppressors over a predetermined time based on anoutput from the power contactor.
 3. The arc suppressing circuit of claim2, wherein the first phase-specific arc suppressor is configured to notsuppress arcing in the negative domain and the second phase-specific arcsuppressor is configured to not suppress arcing in the positive domain.4. The arc suppressing circuit of claim 3, wherein the firstphase-specific arc suppressor comprises a latching switch configured tocause the first phase-specific arc suppressors to not suppress arcing inthe negative domain.
 5. The arc suppressing circuit of claim 4, whereinthe latching switch is a thyristor.
 6. The arc suppressing circuit ofclaim 2, wherein the coil lock controller comprises: a power convertercoupled over a coil interface; a rectifier coupled to the powerconverter; a power limiter coupled to the rectifier; a power storagecoupled to the power limiter; and a current supply coupled to the powerstorage, the current supply coupled to the first phase-specific arcsuppressor and the second phase-specific arc suppressor.
 7. The arcsuppressing circuit of claim 6, wherein the power converter comprises anRC circuit, the rectifier comprises a diode array, the power limitercomprises a Zener diode; the power storage comprises a capacitor; andthe current supply comprises a MOSFET transistor.
 8. The arc suppressingcircuit of claim 4, wherein each of the first and second phase-specificarc suppressors comprise a coil lock, coupled to the coil lockcontroller, configured to disable a respective one of the first andsecond phase-specific arc suppressors based on an input from the coillock controller.
 9. The arc suppressing circuit of claim 8, wherein thecoil lock comprises a signal isolator emitter coupled to the coil lockcontroller and a signal isolator detector coupled to the latchingswitch.
 10. The arc suppressing circuit of claim 9, wherein the coillock is a photorelay comprising the signal isolator emitter and thesignal isolator detector.
 11. The arc suppressing circuit of claim 8,wherein each of the first and second phase-specific arc suppressorscomprises: a signal edge detector; an edge-pulse converter in serieswith the signal edge detector; a current limiter in series with theedge-pulse converter; and a first over voltage protection coupled to theedge-pulse converter and the signal isolator detector of the coil lock.12. The arc suppressing circuit of claim 11, wherein the edge-pulseconverter is at least one of: a transformer; a pulse transformer; or agate trigger.
 13. The arc suppressing circuit of claim 2, wherein eachof the dual unidirectional arc suppressors further comprises: a firstcontact terminal configured to be electrically coupled to a firstcontact of the power contactor; a second contact terminal configured tobe coupled to be electrically coupled to a second contact of the powercontactor, the second contact terminal coupled to the firstphase-specific arc suppressor, the second phase-specific arc suppressor,and the coil lock controller; and a fusible element coupled between thefirst contact terminal and the first phase-specific arc suppressor, thesecond phase-specific arc suppressor, and the coil lock controller. 14.The arc suppressing circuit of claim 13, wherein the fusible element isone of: a solder mask, a silkscreen, a passive fuse, or an active fuse.15. The arc suppressing circuit of claim 13, wherein each of the dualunidirectional arc suppressors further comprises a second over voltageprotector coupled over the first phase-specific arc suppressor, thesecond phase-specific arc suppressor, and the coil lock controller. 16.The arc suppressing circuit of claim 15, wherein the second over voltageprotector comprises at least one of: variostor, a transient-voltagesuppression (TVS) diode, a Zener diode, a gas tube, or a spark gap. 17.A method of suppressing arcing across a power contactor coupled to analternating current (AC) power source having a predetermined number ofphases, each contact of the power contactor corresponding to one of thepredetermined number of phases, the arc suppressing circuit comprising:coupling a number of dual unidirectional arc suppressors equal to thepredetermined number of phases of the AC power source across the powercontactor, each dual unidirectional arc suppressor comprising: a firstphase-specific arc suppressor configured to suppress arcing across theassociated contacts in a positive domain; a second phase-specific arcsuppressor configured to suppress arcing across the associated contactsin a negative domain; and a coil lock controller configured to inhibitoperation of the first and second phase-specific arc suppressors over apredetermined time based on an output from the power contactor.
 18. Themethod of claim 17, wherein the first phase-specific arc suppressor isconfigured to not suppress arcing in the negative domain and the secondphase-specific arc suppressor is configured to not suppress arcing inthe positive domain.
 19. The method of claim 18, wherein the firstphase-specific arc suppressor comprises a latching switch configured tocause the first phase-specific arc suppressors to not suppress arcing inthe negative domain.
 20. The method of claim 19, wherein the latchingswitch is a thyristor.
 21. The method of claim 20, wherein the coil lockcontroller comprises: a power converter coupled over a coil interface; arectifier coupled to the power converter; a power limiter coupled to therectifier; a power storage coupled to the power limiter; and a currentsupply coupled to the power storage, the current supply coupled to thefirst phase-specific arc suppressor and the second phase-specific arcsuppressor.